How to Calculate the Cheapest Print on Demand Option, Not Just the Sticker Price

Every "cheapest print on demand" search eventually runs into the same trap: comparing sticker prices that are not actually comparable. One supplier's $15 tee has shipping added at checkout. Another's $18 tee includes shipping but requires a 12-piece minimum. A third's $19.88 tee has neither add-on. The only way to actually answer "what is the cheapest option" is to run a simple true-cost formula instead of comparing the number on the product page.

The True-Cost Formula

For any print on demand quote, the real cost per piece is:

True cost = base price + shipping charged (if any) + per-color or setup fee (if any) + (unused units from a forced minimum order / units actually needed)

Run this once for any supplier you are comparing and the sticker price stops mattering nearly as much.

A Worked Example: $15 Shirt vs $19.88 Shirt

Supplier	Sticker price	Shipping	Minimum order	True cost for 6 shirts needed
Supplier A	$15.00	$7.00 added at checkout	None	$22.00/shirt
Supplier B	$12.00	Free	24-piece minimum	$48.00/shirt (24 ordered, 6 used)
Bear Grips	$19.88	Free	None	$19.88/shirt

The $15 and $12 sticker prices both look cheaper than $19.88 until the formula runs. Neither supplier in this example is actually the cheaper option for a 6-shirt order once shipping and the forced minimum are counted.

Bear Grips Pro Shops: Custom Apparel for Your Team. No Minimums. Free Shipping.

Why Comparing Sticker Price Alone Misleads Almost Everyone

• Shipping is often left off the first quoted number. It shows up at checkout, after the comparison has already been made in your head.
• Minimum orders hide the real per-unit cost. A $12 shirt with a 24-piece minimum is not a $12 decision, it is a $288 decision, whether you need 24 shirts or not.
• Setup and per-color fees rarely appear on the product page. They show up on the invoice or the design-upload step instead.

Running the Formula for Your Own Order

Before comparing any two print on demand options, confirm three numbers: the base price, whether shipping is included, and whether there is a minimum order. At Bear Grips, that formula is simple because two of the three variables are fixed at zero: no shipping charge and no minimum order, on every one of the 63 products. The only variable left is the base price itself, which starts at $19.88 VIP base. See the red flags buying guide for the fuller checklist, or run your own numbers at Bear Grips Pro Shops.

Frequently Asked Questions

What is the actual cheapest print on demand option?

The one with the lowest true landed cost for your specific order size, not the lowest sticker price. Always factor in shipping and any minimum order requirement.

Why does a higher sticker price sometimes end up cheaper?

Because free shipping and no minimum order remove two cost variables that a lower sticker price often hides until checkout.

Does Bear Grips charge for shipping or have a minimum order?

No to both. Shipping to the end customer is free and there is no minimum order on any product.

How many shirts do I need before a bulk minimum becomes worth it?

Generally 50 or more identical pieces ordered at once with no expected reorders. Below that, single-piece ordering usually has the lower true cost.